A composite model has been developed to simulate the extrusion process for intermeshing counter-rotating twin-screw extruders. An experimentally based inciting model, solids conveying model, and new improved metering model, were combined to develop this formulation. The procedure for global design of a flood feed intermeshing counter-rotating twin screw extruder is presented. Illustrative calculations are made for polyvinyl chloride and high density polyethylene in this type of machines with different screw designs. Computations are made for axial variation of the fill factor, pressure, temperature and melting profiles. Simulations were found to match with experimental results well. The model was also applied to scale-up.